Contact sulphuric acid process



Patented Apr. 14, I936 UNlTlS-D STATES PATENT OFFICE CONTACT SULPHURIC ACID PROCESS.

ware

N 0 Drawing.

Original application March 10, 1927, Serial No. 174,414,

Divided and this application August 17, 1928, Serial No. 300,384

6 Claims.

This invention relates to processes for the production of sulphuric acid and sulphur trioxide by the contact sulphuric acid process.

In the patents of .Alphons O. Jaeger and Johann A. Bertsch, No. 1,657,754 patented January 31, 1928, and No. 1,657,753 patented January 31, 1928 and co-pending application Serial No. 88,488, filed February 15, 1926, Patent 1,696,546, processes are described for the catalytic oxidation of sulphur dioxide by means of zeolite catalysts, in which the catalytically effective element is chemically combined in non-exchangeable form in the zeolite itself. The processes may use zeolites which are undiluted or those which are diluted with various relatively inert substances, such as kieselguhr, pumice, and other carriers, either in a finely divided state or in the form of massive fragments. I have found that catalysts of great effectiveness possessing substantially all of the advantages of the zeolite catalysts, described in the application and patents hereinabove mentioned, can be obtained by introducing catalytically effective diluent bodies into zeolites and other base exchange bodies which are not themselves catalysts for the contact sulphuricacid process. The present invention possesses the advantage that it is not necessary to chemically combine the catalytically effective components in the zeolite structure and it is, therefore, possible to exercise a wide margin of choice in the catalytic component used. Apparently, the physical structure of the zeolite, coupled with its chemical characteristics, is effective, whether the catalytically effective component is itself .chemically combined with the zeolite or merely associated therewith, preferably in a uniform and homogeneous manner. It is thus possible to utilize many valuable effective catalysts which could not be incorporated chemically in any zeolite. Thus, for example, I have found thatmany salts of vanadic acid, such as, for example, iron salts, silver salts, and the like, are extraordinarily effective catalysts when used as diluent bodies for zeolites which are .not themselves catalytically effective. In addition to salts of vanadic acid, such as iron vanadate and silver vanadate, which are known to be fair catalysts, other salts of vanadic acid, such as copper, cobalt, nickel, uranium, titanium, manganese, chromium, aluminum beryllium, zirconium and cerium vanadates, which are not normally considered as catalysts, when united with a base exchange body act as very effective catalysts. Not-only, therefore, does the present invention permit the more effective usage of known catalysts, but it also transforms lysts into highly effective contact masses. salts of vanadic acid cannot, of course, be catalytipossess all of the advantages of zeolites.

-mercially satisfactory yields.

vanadic acid salts which are not usable as cata- Such cally combined with the zeolite, and, therefore, the field of available catalysts is greatly increased due to the fact that it is not necessary to restrict oneself to products which can be chemically incorporated in a zeolite or other base exchange body. I am not sure why the zeolites, which are themselves not catalysts or at any rate not effective catalysts, can transform such catalysts as, for example, salts of vanadic acid, into contact masses of extraordinary activity. I was formerly of the opinion that it was necessary to chemically combine the catalytically effective component with the zeolite itself, and this opinion is expressed in the joint application and patents above referred to. Whether or not this may be the reason for the catalytic efficiency of the zeolites there described is not definitely proven, but I am of the opinion that this factor is not the only one and perhaps not the most important one in determining whether or not a particular zeolite complex is an efficient catalyst. I am now of the opinion that the physical structure of the zeolite is perhapsof greater importance than the chemical combination of the zeolite with the catalytic elements. It seems probable, however, that the zeolite does not act purely as a microporous inert carrier, since other carriers of comparable porosity do not I am, therefore, of the opinion that the zeolite also acts as a chemical activator of the catalyst, although not chemical-1y combined therewith. I believe that the high molecular silicic acid complex of the zeolite constitutes an important chemical activator or promoter, which enhances the activity of the catalyst embedded therein, apart from its physical characteristics. The above explanations are not in any sense intended to limit the invention, but merely constitute the best explanation which I .know at the present time to account for the remarkable effectiveness of the. catalysts which are prepared according to the present in- .vention, an effectiveness which far exceeds the sum of the catalytic effectiveness of the zeolite itself and the catalyst embedded therein.

In the following specification and claims, a sharp distinction will be drawn between substances which are actual practical catalysts for contact sulphuric acid and other substances, which, while they may have a certain amount 'of catalytic activity, are nevertheless incapable by themselves of acting as catalysts giving com- Thus, for example, certain iron zeolites may be used for the catalytic oxidation of sulphur dioxide, but cannot be used practically as the yields run but little above 50 or 60%. In the present application, therefore, an effective catalyst will be defined as one which is capable of giving yields better than 70 or 75% under ordinary operating conditions. This line is not drawn on a basis of actual chemical differences, but constitutes one of practical utilization. It should be understood also that when a diluent is spoken of as a catalytically effective diluent, what is meant is that a diluent when incorporated or associated with a zeolite is capable of giving satisfactory yields in a contact sulphuric acid process. In many cases, the diluent used alone would not be an effective catalyst within the meaning of the term as used in the present specification.

In the present invention, any zeolite or base exchange body which is not itself an effective catalyst may be used; In addition to the ordinary zeolites which are base exchanging polysilicates, the reaction products of two kinds of reacting components, there are also included base exchanging polysilicates which are the reaction products of more than two kinds of components, and which for simplicity will be hereinafter referred to as multi-component zeolites, and base exchange bodies which do not, contain silicon and which will be referred to as non-silicious base exchange bodies. The words base exchange body will be used generally to cover these three classes. It should be understood that I do not claim herein the multi-component zeolites and non-silicious base exchange bodies as new chemical compounds, this constituting the subject matter of my co-pending application, Serial No. 142,783, filed October 19, 1926, and Serial No. 171,727, filed February 28, 1927.

The base exchange body containing a catalytically effective diluent may or may not constitute a single base exchange body and a mixture of a plurality of base exchange bodies belonging to one or more of the above indicated classes may be used. A plurality of catalytically effective elements may also be incorporated with or without further diluents, which may be inert or which may act as activators, promoters or stabilizers of the catalyst components themselves.

The base exchange bodies can be prepared in a wet form or by fusion methods as is well known to the art and as has been described in my copending applications above referred to, and also in the co-pending joint applications of A. O. Jaeger and J. A. Bertsch, Serial No. 100,116, filed April 6, 1926, Serial No. 95,771, filed March 18, 1926 and Serial No. 91,229, filed February 27, 1926.

In every case, however, the base exchange bodies retain their advantageous high absorptive and adsorptive characteristics, their mechanical strength, and honeycomb-like microporous structure. They are also in many cases chemical activators or may be considered also as physical activators, due to the fact that the minute capillary pores with their enormous surface energy bring the reacting gases in higher concentration under higher partial pressures into contact with uniformly distributed, catalytically effective components under such conditions as to prevent, to a great extent, local overheating and consequent injurious effect on the reaction equilibrium.

There are a number of methods of introducing 'diluents into a base exchange body and one or other of these methods can be employed in the 'into base exchange bodies.

case of catalytically effective diluents which are included under the present invention.

1. The catalytically effective diluents may be mixed with one or other of liquid components of the base exchange body to be formed when the latter is prepared by wet methods.

2. The catalytically active components can be precipitated or incorporated by impregnation or by any other manner into diluent bodies which are themselves not catalytically effective and which may be inert, activating, stabilizing or promote stabilization. These diluent bodies are then incorporated into the base exchange body or by any of the other suitable incorporation methods.

3. The catalytically effective diluents are to be mixed with the base exchange bodies when the latter are in the form of gels by kneading or stirring, in which case the base exchanging gel may be considered more or less as an adhesive. The homogeneity and uniformity of the distribution of the catalytically efiective element is, of course, not as great by this method as by methods 1 and 2, but for many purposes extreme uniformity is not necessary and may even be undesirable.

4. The catalytically effective components may be formed during the formation of the base exchange body in the same by mixing suitable components with the components of the base exchange body so that the reaction, whereby the latter is formed, will also form the catalytically efiective diluent particles. The addition of protective colloids may be desirable to prevent coagulation of the diluent particles before the base exchange body has become sufficiently set.

5. A somewhat similar method to 4 can be used in which part of the base exchange body components react with the catalytically effective components during base exchange body formation to produce the necessarycatalytically effective particles. Thus, for example, salts of vanadic acid can be introduced into a base exchange body by using an excess of a metal salt component during base exchange body formation to react with and form salts of vanadic acid.

6. Ready prepared base exchange bodies, diluted or undiluted, artificial or natural, can be impregnated with true or colloidal solutions of the catalytically effective components, the product thereafter being dried.

7. A ready prepared base exchange body, diluted or undiluted, may be impregnated with a plurality of solutions which react therein to precipitate the catalytically effective diluent.

8. Soluble, catalytically eifective compounds can be added to the components forming a base exchange body which after formation retains the catalytically effective component in solution and is dried without washing or is treated to precipitate the catalytically effective compound.

9. The natural or artificial base exchange bodies, diluted or undiluted, may be impregnated with solutions of catalytically effective compounds which are then precipitated by treatment with gases.

The above nine methods briefly recapitulate the general methods of incorporating diluents Of course, other means may be used and particularly a combination of two or more of the above described methods may be utilized and is frequently desirable. In general, any of the methods described in the co-pending application of Jaeger and Bertsch, Serial No. 95,771, filed March 18,

manganesaberyllium, aluminum, titanium, iron, copper, .ziroonium, .zinc, lead,

1926, can be employed mutatis mutandis, to introduce catalytically effective diluents into base exchange bodies or mixtures of base exchange bodies.

The diluted base exchange bodies of the present invention may be further treated with salt solutions to introduce bases in exchangeable form, which bases may themselves have some catalytic activity, but which are usually of an activating or stabilizing nature or promote the stabilization of catalysts. The base exchange body after formation may also be treated with compounds containing acid radicals which are not in themselves effective catalysts to form the so-called salt-like bodies with the base exchange body.

The base exchange bodies may be incorporated with diluents by a fine mechanical mixture, followed by forming into workable fragments by means of a suitable adhesive. In general, however, this method of preparation does not produce a uniformly fine and homogeneous subdivision of the catalytically effective component with the base exchange body, and contact masses so produced are generally not as efficient as those prepared by the wet methods referred to hereinabove. Nevertheless, however, it is possible to make contact masses by this method and they are included in the scope of the present invention. It should be also understood that many of the nine methods described above in connection with base exchange bodies prepared by wet processes can also be utilized in connection with the well known fusion processes for the production of base exchange bodies. The applicability will be obvious to the skilled chemist.

In general, it should be understood that contact masses of the present invention contain at least two kinds of components, namely, a catalytically effective component physically combined with a base exchanging component which is not itself an effective catalyst. The contact masses may, however, in addition to these two components, contain others, such as diluents of a porous or other nature, chemical compounds admixed mechanically or united by physical means with the contact mass, or produced by treatment thereof, which act as stabilizers and tend to smooth out undue violence of reaction. Notably, compounds which are salts of alkaliforming and similar metals, such as earth metals, act as stabilizers. Certain other compounds, notably compounds of many amphoteric metals and compounds which contain silicic acid, appear to enhance and amplify the stabilizing effect of the salts of the basic metals and these compounds I have termed stabilizer promoters. Obviously, of course, in many cases, a single component may perform more than one function. Thus, a zeolite may act as a base exchange body with its desirable, physical structure and it may, by virtue of the alkali contained therein, act also as a stabilizer, and, by virtue of the silicic acid present, act as a stabilizer promoter. All such products, when used for the catalytic oxidation of sulphur dioxide, are included within the present invention.

Among the elements from which catalytically effective components can be prepared are the metal elements of the th and 6th groups of the periodic system such as vanadium, molybdenum, tungsten, uranium, chromium, manganese, arsenic, antimony, tantalum, niobium and bismuth. In addition to these particularly catalytic elements, other metal elements such as silver, cerium, nickel, cobalt, boron and the rare earths may be associated and enhance the activity of the catalyst in many cases. The most'important catalytically effective components are those which contain platinum and vanadium, such as, for example, metallic platinum, platinum compounds, and theoxides, salts and other compounds of thetrivalent, tetravalent and pentavalent vanadium. 'Some particularly effective salts are the vanadates and vanadites ofthe metals such as iron, copper, silver, nickel, cobalt, titanium, zirconium, cerium, aluminum, calcium, cadmium, uranium, chromium, manganese, etc. Vanadic oxide is also an important catalytic component. It should be borne in mind that the amount of the catalytic component is relatively small in comparison with the mass or more particularly the volume of the contact .mass as a whole and in general the catalytically effective component will not exceed 5 or 10% of the total weight of the contact mass.

The additional diluent bodies with which the catalytically effective components can be associated in the base exchange body are not limited and any suitable diluents can be used. I have found that diluents which have high adsorptive and absorptive powers act as activators by reason of their physical characteristics and are very desirable. The particle size of the diluents may vary within wide limits, but 'I have found that finely divided diluents, particularly those less than 60 microns are advantageous as they produce a more homogeneous product. Among the diluents may be mentioned kieselguhrs of all kinds, with or without preliminary treatments, fullers earth, talc, pulverized catalytically ineffective base exchange bodies of natural or artificial origin, rocks, stones, tuffs, trass, lava, etc.,

of volcanic or eruptive origin, green-sand, slag wool, pulverized slag, cement, silica gel, quartz filter stones, pulverized earthenware, pulverized natural or artificial silicates, .glasspowder, graphite, pulverized minerals rich in quartz, pumice lytically effective components and associated compounds are properly chosen, are of extraordinary effectiveness. The physical characteristics of the products, of course, will vary in accordance with the conditions under which they are prepared and any of the general methods and conditions described in the applications mentioned above of Jaeger and Bertsch, Serial No. 100,116, filed April 6, 1926, Patent 1,782,353, Serial No. 95,771, filed March 18, 1926, Patent 1,840,450, and Serial No. 91,229, filed February '27, 1926, Patent 1,701,075, and my co-pending applications, Serial No. 142,783, filed October 19, 1926, Patent 1,728,732 and Serial No. 171,727, filed February 28, 1927, will be used and are illustrated in the examples.

In general, the contact masses to be used for the oxidation of sulphur dioxide should be given preliminary treatment with air or S02 containing gases or both. The catalytic reaction brings about certain changes in the chemical composition of the base exchange bodies, without, however, afiecting their physical structure. Therefore, I do not wish to be understood as maintaining that the catalysts remain unchanged during the reaction and they are defined as of the time of preparation as is customary in catalytic chemistry. These secondary transformations are sometimes relatively ineffective; in other cases, they may be important in controlling the catalytic eificiency of the mass. Thus, for example, during the contact sulphuric acid process, the S03 produced will usually react with the base exchange bodies present and will react with the alkali present, forming certain alkali bisulphates or bisulphates of the exchangeable bases which may be present. These compounds for the most part are stabilizers so that in many cases the reaction itself produces in the catalyst the necessary stabilizer. Where a great amount of stabilizer is required, it may be added in the form of the desired salt or the basic oxide may be added and further amounts of stabilizer produced by the reaction itself.

The invention will be illustrated in detail in the following examples, which are to be understood merely as illustrations of certain methods of carrying out the principles of the invention, Which is in no sense limited tothe exact details therein set forth. It should be understood, how- .ever, that in many of the examples, specific features of great value are described and such features are included in the narrow and preferred embodiments of the invention, although they do not limit its broad scope. The features are pointed out hereinafter in the appended claims.

Example 1 12 parts of V205 are dissolved by means of 12.4 parts of KOl-I in 200-250 parts of water, and 80 parts of infusorial earth are stirred in. The suspension obtained is then treated with 7.12 parts of ferric chloride dissolved in to parts of water, the temperature being maintained at about 40 to 50 C. After all the ferric chloride has been added, the reaction mixture is made neutral to litmus by the gradual addition of 2N sulphuric acid. A mixture of ferric vanadate and infusorial earth is obtained, which is separated from the mother liquor by filtration, and is then Washed with 200 parts of cold water. 90.5 parts of 33 B. waterglass are diluted with four to five volumes of water, and the filter cake containing ferric vanadate and infusorial earth is added with vigorous stirring in order to obtain a uniform distribution. 60 parts of aluminum sulphate with 18 mols of water are dissolved in 200 parts of water and sufficient N/ 10 potassium hydroxide solution is added todissolve up the aluminum oxide which is at first precipitated, forming a potassium aluminate solution. The aluminate solution is then stirred into the suspension and the mixture heated up to about 60 C. A gelatinous precipitate is obtained almost at once, and is increased by the gradual addition of 2N sulphuric acid. Care should be taken, however, that a weak alkalinity to phenolphthalein is maintained. The stirring is continued for an hour, the mixture being gradually permitted to cool down to room temperature. The gelatinous precipitate obtained is pressed and washed with 200 parts of water in small portions. The yellow filter cake is then dried at about 80 C., and broken into fragments of suitable size.

Two to four volumes of the contact mass thus produced are placed in a contact sulphuric acid converter and a thousand to two thousand volumes of 7-9 per cent burner gases are passed over the catalyst per hour at temperatures of about 450 to 500 C. A yield of 96 to 98.5% of the theoretical is obtained. The catalyst is very resistant to high temperatures.

Instead of using iron vanadate as a diluent in the zeolite formed, other catalytically active salts of vanadium, such as the vanadites or trivalent vanadium salts may be substituted.

Equivalent amounts of salts of tetravalent and pentavalent vanadium, such as, for example, the nickel, cobalt, manganese, uranium, copper, aluminum, titanium, silver, barium or calcium salts, may be used, either singly or in admixture, as catalytically active diluents in the z-eolite. These catalysts are capable of giving yields up to 98.5% of the theory under reaction conditions as outlined above.

In order to increase the resistance of these the zeolite is a carrier can also be coated or af- 1.

fixed to massive carrier fragments, such as, for example, burnt pyrites, titanium dioxide, ilmenite, bauxite, chromium oxide, manganese dioxide, copper dioxide, materials rich in silicic acid such as roughened fragments of quartz, flint, pumice fragments, broken quartz filter stones; or artificial carriers rich in silicic acid, such as for example carriers prepared from kieselguhr and waterglass, kieselguhr and potassium aluminate, zeolites, kieselguhr and alkalies, or alkali salts and the like. Metals and metal alloys may also be used, such as, for example, aluminum granules, roughened fragments of ferrovanadium, ferromolybdenum, ferrosilicon, siliconferromanganese, silicon-aluminum-ferromanganese, ferrotitanium, ferrotungsten, and the like. These contact masses can be prepared by causing the waterglass-infusorial earth-iron vanadate suspension to adhere to the carriers, and then forming the zeolite by the addition of the aluminate solution, or by spraying with an aluminum sulphate solution, in which case a zeolite is produced which is of the aluminum double silicate type.

It is sometimes advantageous in preparing contact masses to introduce diluent bodies, which can then be removed by washing or by calcining. Thus, for example, 5 to 10% of flour, starch or sugar can be incorporated into the catalyst during the formation of the zeolite and later removed by washing or calcining, leaving still further pores in the contact masses, and thereby increasing its effectiveness as a catalyst.

The salts of tetravalent and pentavalent vanadium can also be substituted partially by salts of the oxygen containing acids of the metals of the fifth and sixth groups of the periodic system, as, for example, tantalum, tungsten, molybdenum and chromium. Where, however, highly eifective catalysts are desired, the substitution of these other catalytic components should not exceel 10 to 15%.

It should be understood in general that the catalysts of the following examples can also be coated onto the massive carrier fragments, as

has been described in detail in connection with the catalysts of the present example.

Example 2.

18.2 parts of V205 are dissolved in the least quantity of normal sodium hydroxide solution, in order to form the sodium metavanadate. 34 parts of silver nitrate dissolved in 250 parts of water are then added with vigorous stirring, precipitating out the yellow silver vanadate. precipitate is permitted to settle, decanted several times with water to remove the sodium nitrate formed, and then 500 parts of a 33 B. potassium waterglass solution diluted with eight to ten volumes of water are added. 42.5 parts of aluminum oxide are dissolved in 2N potassium hydroxide to form potassium aluminate, and this solution is then poured into the silver vanadatewaterglass suspension with vigorous agitation, the temperature being maintained. at about 40-50 C. In a short time considerable amountsof aluminum zeolites are formed, and the yields are greatly increased by a cautious addition of N/2 sulphuric acid, care being taken that a weakly alkaline reaction to phenolphthalein remains after the last addition of sulphuric acid. The zeolite containing silver vanadate in a fine state of division is then pressed in the usual manner, dried at temperatures up to 80, and hydrated by causing four to five volumes of water to trickle over it." The hydration causes the product to break up into small fragments, which are then treated with a 5% calcium chloride or strontium chloride solution, in order to substitute part of the alkali of the zeolite of calcium or strontium.

Instead of using 42.5 parts of aluminum oxide in the form of a potassium aluminate solution, 28.3 parts of aluminum oxide may be so used, together with 14.2 parts of aluminum oxide in the form of a 5% aluminum sulphate solution. The potassium aluminate solution is first added to the waterglass-silver vanadate suspension, and then the aluminum sulphate solution is added with vigorous agitation, the reaction mixture solidifying to a thick gel of'a so-called multi-component zeolite, in which silver vanadate is present as a catalytically effective diluent.

Aluminum oxide, which behaves as an amphoteric metal oxide in this composite catalyst, can also be substituted partly or wholly by other amphoteric metal oxides, especially beryllium oxide, cadmium oxide and chromium oxide.

These oxides maybe introduced partly or wholly either in the form of the alkaline metal metallates or in the form of metal salts. Instead of silver vanadate, other vanadates of the heavy metals can be used ascatalytically effective diluents. Similar salts of tetravalent vanadium are also effective. In general, such contact masses which contain about to of catalytically effective diluents are excellent contact masses for catalytic oxidation ofsulphur dioxide. 7% burner gases freed from dust, but containing the so-oalled catalyst poisons are passed over these contact masses at 450-550 0., and in a short time an excellent contact sulphuric acid process begins, giving yields up to 96% of the theory.

7 Example 3 15 parts of V205 are dissolved in a solution containing 15 parts of 90% sodium hydroxide in 250 "parts ofwater. About 70 parts of diatomite brick refuse of Celite is stirred in, and the mixture heated to 50-60" C. A ferric chloride solution containing 9parts of ferric chloride in 150 parts of water is then added with vigorous agitation, and after all the ferric chloride has been added the reaction mixture is rendered neutral to litmus by means of 2N sulphuric acid, and permitted to cool down to room temperature. A diluted iron vanadate precipitates out and is sucked and washed.

200 parts of 33 B. waterglass are diluted with 400-600 parts of water, and the iron vanadate filter cake-suspended therein. 26.4 parts of ferric sulphate with 9 mols of water are dissolved in 250 parts of water, or instead of the ferric sulphate solution asolution containing 29.3 parts of manganese sulphate with 4 mols of water can be prepared, or an equivalent mixture of ferric and manganese sulphates may be used. The ferric sulphate solution or manganese sulphate solution is then introduced into the waterglass-iron-vanadate suspension with vigorous agitation, the whole mass soon solidifying to a yellow gelwhich shows an alkaline reaction to phenolphthalein. The gel is recovered from the mother liquor in the usual way by pressing and drying at temperatures under 100 C., and contains an iron zeolite in which both catalytically effective and catalytically indifferent diluents are embedded.

The contact mass is broken into fragments and first blown with air, the temperature gradually rising to 450 C. Thereupon the contact mass is treated with gases containing 4 to 6% of S02 and air, and constitutes an effective catalyst for the contact sulphuric acid process. The contact mass is extraordinarily resistant to high temperatures and retains its effectiveness.

Example 4 A diluted aluminum zeolite is formed by introducing 60 to 80 parts of finely ground silicate rock, burnt pyrites or infusorial earth into 90 to 100 parts of a 33 B. waterglass solution which has been diluted with 300-500 parts of water, and which is then caused to react with a potassium aluminate solution prepared by adding sufficient half normal potassium hydroxide solution to an aluminum sulphate solution containing 55 parts of aluminum sulphate with 18 mols of water in 200 parts of water until the aluminum hydroxide which at first precipitates is again dissolved in the form of potassium aluminate. The reaction is aided by warming up the mixture to 40-5 0 C. and increased yields obtained by gradual addition of 2N sulphuric acid. The product is a diluted aluminum zeolite, which is not an effective catalyst for the contact sulphuric acid process. Instead of the two-component aluminum zeolite, a three-component aluminum zeolite can be prepared, in which part of the aluminum is introduced in the form of an alkali metal aluminate and the other part in the form of an aluminum salt.

An aluminum zeolite of the character of an aluminum double silicate can also be prepared by causing an aluminum sulphate solution to react with the waterglass solution, to which suflicient alkali has been added so that when all of the aluminum sulphate has been introduced the mixture still reacts alkaline to phenolphthalein.

Instead of the aluminum oxide component, other amphoteric metal oxides in the form of salts or metallates can be used, for example, oxides of beryllium, cadmium, Zirconium, zinc and titanium, singly or in mixtures. These amphoteric metal oxides may also be used in conjunction with aluminum.

The diluted zeolites are broken into fragments, impregnated at an elevated temperature with 12 parts of V205 in the form of an ammonium vanadate solution, and then impregnated with 7.12

parts of ferric chloride dissolved in 100-150 parts of water. The product is again dried, and constitutes a zeolite impregnated with iron vanadate. The zeolite is calcined in order to remove the ammonium-chloride formed, which results in a still further increase in the porosity of the product, and is then treated with 7% burner gases, an excellent contact sulphuric process soon setting in.

In a similar manner, other salts of vanadic acid can be used, such as, for example, copper vanadate, silver vanadate, manganese vanadate, titanium vanadate, cobalt vanadate or nickel vanadate, either alone or together with iron vanadate. Mixtures of these salts may, of course, also be used.

It is possible also to substitute part of the vanadates by the corresponding tungstates or molybdates. Salts of tetravalent vanadium acids may also be used.

Example 5 A zeolite is prepared as describedin Example 4, but instead of drying the gels they are at once mixed with salts of tetravalent or pentavalent vanadium, singly or in admixture, with salts of other oxygen metal acids, such as tantalates, tungstates, chromates and molybdates, the salt components being kneaded into the gel. After drying and treating in the usual manner, excellent catalysts for the contact sulphuric acid process are obtained.

Example 6 400 parts of 33 B. waterglass are diluted with 6 to 8 volumes of water, and 497 parts of ferric sulphate containing 9 mols of water dissolved to form a 10% aqueous solution are added, producing an iron silicate which does not show any base exchanging powers. Into this iron silicate either wet or after drying, iron vanadate is introduced either ready prepared or in the form of components which cause its formation in situ. The iron vanadate may be prepared by dissolving 15 parts of V205 in about 15 parts of sodium hydroxide and adding 15 parts of ferric sulphate with 9 mols of water in the form of a 15% solution. parts of 33 B. waterglass are diluted with 6 to 7 volumes of Water, and the iron silicate containing iron vanadate is stirred in to form a homogeneous suspension. 55 parts of aluminum sulphate with 18 mols of water are dissolved in 250 parts of water and normal potassium hydroxide solution is added until a clear potassium aluminate solution is obtained. Instead of using all of the aluminum in the form of an aluminate solution, part may be used as aluminum sulphate, in which case it will not be necessary at a later point to add acids to neutralize the excess of alkali in the zeolite components. The waterglass suspension and the aluminate solution are poured together, and the zeolite precipitated either by means of normal sulphuric acid or if part of the aluminum is present in the form of aluminum sulphate a three component zeolite is formed. The aluminum can be partly or wholly substituted by beryllium, cadmium or zirconium, singly or in mixtures.

The gel obtained is pressed in the usual manner, dried at temperatures below 100 0., broken into fragments and hydrated by permitting 400 to 500 parts of water to trickle over it. After Example 7 55 parts of aluminum sulphate containing 18 mols of water are dissolved in 300 parts of water, to which is added a solution containing 1'7 parts of ferric sulphate with 9 mols of water in 200 parts of water. An 8% sodium metavanadate solution is poured into the aluminum and iron sulphate solutions until 16 parts of V205 have been added. Vigorous agitation should be maintained, and a precipitate of iron-aluminum vanadate results, the precipitate being in a fine state of subdivision. parts of 33 B. waterglass diluted with 5 to 6 volumes of water are mixed with 60 to- 80 parts of diatomite brick refuse, and the iron-aluminum vanadate is then added, together with sufficient normal potassium hydroxide solution so that after all of the vanadate suspension is added the mixture is still strongly alkaline to litmus. A zeolite is thus obtained in which the catalytically eifective component is in the form of a diluent, and the product is worked up in the usual manner by pressing, washing with 400-600 parts of water and drying under 100 C. The contact mass is broken into fragments, calcined, and when treated with 6-9% burner gases at 430-480 C. gives excellent yields of sulphur trioxide up to 98% of the theoretical.

In a similar manner, other salts of vanadic acid or salts of tungstic and molybdic acids, for example, the silver, titanium, calcium, copper, cobalt, nickel or manganese salts may be used, singly or in mixture. After hydrating, these contact masses may also be treated with 5% silver nitrate or copper nitrate, in order to introduce these elements into the zeolite in exchangeable form.

Example 8 Instead of carrying out the reaction as described in Example 7, a potassium metavanadate solution, containing 16 parts of V205, is added to the diluted waterglass solution and then a solution containing 55 parts of aluminum sulphate with 18 mols of water and 1'7 parts of ferric sulphate with 9 mols of water are added, the reaction mixture remaining strongly alkaline to litmus. Most of the potassium vanadate is transformed into aluminum-iron vanadate, and is embedded in a very finely divided form in the zeolite. These contact masses when treated as described in Example 8 are excellent for the contact sulphuric acid process.

Example 9 date, lithium vanadate, caesium vanadate, rubidium vanadate, and then sprayed with dilute sulphuric acid or treated with gases containing sulphur trioxide forming V205 in a finely divided state in the zeolite structure. These products are excellent catalysts for contact sulphuric acid.-

The proportions of the impregnated salts may vary considerably, but in general I have found that the amount of V205 present should be about 10 to 15% by weight.

Example 10 10.2 parts of aluminum oxide are dissolved by means of 40 parts of 100% KOH in 300 parts of water. -80 parts of kieselguhr are then impregnated with an ammoniacal silver vanadate solution prepared from 18.2 parts of V205, and 34 parts of silver nitrate dissolved in 20% ammonia water. After impregnation is complete the ammonia is removed by heating. The kieselguhr-silver vanadate mixture is stirred into the potassium aluminate solution and then a solution containing 37 parts of ferric sulphate containing 9 mols of water in 250 parts of water is added with vigorous agitation, producing a nonsilicious base exchange body, which contains a catalytically effective diluent and also kieselguhr. The thick precipitate formed is pressed, washed with about 200 parts of water in small portions, then dried as usual under C., broken into fragments and calcined. The contact mass so obtained is an excellent sulphuric acid catalyst.

Instead of silver vanadate, copper vanadate, iron vanadate or manganese vanadate can be used, or the vanadate salt can be produced in the acid reaction component, namely, the iron sulphate solution, a corresponding amount of heavy metal salt, that is, either iron sulphate, copper sulphate or silver nitrate being added to react with 18.2 parts of V205 which is added in the form of the alkali metal metavanadate.

This application is a division of my prior copending application, Serial No. 174,414, filed March 10, 1927, now Patent No. 1,694,123, December 4, 1928.

What is claimed as new is:

1. A contact sulphuric acid process, which comprises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass containing a catalytically ineffective base exchange body physically associated with a catalytically effective diluent in homogeneous distribution and containing among its catalytically effective components at least one insoluble compound of a metal of the fifth or sixth groups of the periodic system present in the acid radical of a salt of a metal having a specific gravity greater than 2.

2. A contact sulphuric acid process, which comprises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass comprising a catalytically ineffective base exchange body physically associated with a catalytically effective diluent in homogeneous distribution and containing among its catalytically effective components at least one insoluble salt of an oxyacid of vanadium.

3. A contact sulphuric acid process, which comprises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass comprising a catalytically ineffective base exchange body physically associated with a catalytically effective diluent in homogeneous distribution and containing among its catalytically effective components at least one insoluble metal salt of an oxyacid of vanadium, the metal having a specific gravity greater than 2.

4. A contact sulphuric acid process, which comprises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass comprising a catalytically ineffective base exchange body physically associated with a catalytically efi'ective diluent containing among its catalytically eifective components at least one copper salt of an oxyacid of vanadium.

5. A contact sulphuric acid process, which comprises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass comprising a catalytically inefiective base exchange body physically associated with a catalytically effective diluent in homogeneous distribution and containing among its catalytically effective components at least one insoluble heavy metal vanadate of a metal having gravity greater than 2.

6. A contact sulphuric acid process, which com.- prises passing gases containing sulphur dioxide and oxygen at reaction temperatures over a contact mass comprising a catalytically ineffective base exchange body physically associated with a catalytically effective diluent containing among its catalytically effective components a copper vanadate.

ALPHONS O. J AEGER.

CERTIFICATE OF CORRECTION.

Patent No. 2,037,028. April 14, 1936.

ALPHONS O. JAEGER.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 4, second column, line '71-'72, for "exceel" read exceed; page '7, second column, line 42, claim 5, strike out "heavy metal"; same line and claim, before "gravity" 1 insert a specific; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office Signed and sealed this 8th day of December A. D. 1936.

Henry Van Arsdale (Seal) k Acting Commissioner of Patents. 

